Eddy pump

ABSTRACT

A pump rotor includes a hub, a back plate and a plurality of blades extending from the hub and disposed on the back plate. Each of the plurality of blades has an outer surface essentially parallel to a rotational axis of the hub, and a first end adjacent the hub and a second end distal from the hub, the first end having a height from the planar surface that is less than a height from the planar surface of the second end. The plurality of blades is configured to cause a synchronized central column of flow.

BACKGROUND Field of the Invention

The present invention generally relates to an eddy pump. More specifically, the present invention relates to eddy pump including a rotor that improves pumping performance using a synchronized eddy.

Background Information

Conventional pumps are designed to pump a variety of liquids, materials and slurries (i.e., solids suspended in liquid). One type of conventional pump is a centrifugal pump. In a centrifugal pump fluid or slurry enters axially through a casing, is caught up in the impeller blades, and is tangentially and radially spun outward through a diffuser part of the casing. When pumping slurries, it is important to minimize direct contact of solid material to the impeller, due to wear on the impeller.

SUMMARY

It has been discovered that pump characteristics are improved and wear is minimized by a new pump design that forms a synchronized central column of flow from the pump rotor to the pump inlet and creates a low-pressure reverse eddy flow from the pump inlet to the pump discharge. The new pump design also results in an area of negative pressure near the pump seal. The negative pressure allows the pump to achieve zero (or near zero) leakage.

In view of the state of the known technology, one aspect of the present disclosure is to provide a pump rotor comprising a hub, a back plate and a plurality of blades extending from the hub and disposed on the back plate. The back plate has a planar surface. Each of the plurality of blades has an outer surface essentially parallel to a rotational axis of the hub, a first end adjacent the hub and a second end distal from the hub. The first end has a height from the planar surface that is less than a height from the planar surface of the second end. The plurality of blades is configured to cause a synchronized central column of flow.

Another aspect of the present invention is to provide a pump, comprising a housing and a rotor. The housing has an intake and a discharge. The rotor includes a hub, a back plate, and a plurality of blades extending from the hub and disposed on the back plate. Each of the plurality of blades has an outer surface essentially parallel to a rotational axis of the hub, and a first end adjacent the hub and a second end distal from the hub. The first end has a height from the planar surface that is less than a height from the planar surface of the second end. The plurality of blades is configured to cause a synchronized central column of flow.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the attached drawings which form a part of this original disclosure:

FIG. 1 is a top perspective view of a pump according to one embodiment of the present invention;

FIG. 2 is a top perspective view in section of the pump of FIG. 1;

FIG. 3 is a bottom perspective view in section of the pump of FIG. 1;

FIG. 4 is an elevational view in section of the pump of FIG. 1;

FIG. 5 is a bottom view in section of the pump of FIG. 1;

FIG. 6 is a bottom perspective view of the rotor for the pump of FIG. 1;

FIG. 7 is a top perspective view of the rotor of FIG. 6;

FIG. 8 is a bottom view of the rotor of FIG. 6;

FIG. 9 is a side view of the rotor of FIG. 6;

FIG. 10 is a top view of the rotor of FIG. 6;

FIG. 11 is a cross-sectional side view taken along lines 11-11 in FIG. 10; and

FIG. 12 is a cross-section view of the pump of FIG. 1 illustrating the flow of slurry through the pump.

DETAILED DESCRIPTION OF EMBODIMENTS

Selected embodiments will now be explained with reference to the drawings. It will be apparent to those skilled in the art from this disclosure that the following descriptions of the embodiments are provided for illustration only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.

Referring initially to FIGS. 1, 2 and 12, a pump is illustrated in accordance with a first embodiment. The pump includes a drive motor, a volute or housing and a rotor. The rotor is disposed within the housing such that fluid, liquids, materials and slurries can enter the housing and by pumped by the rotor. The rotor is connected to the drive motor (FIG. 12) that is configured to drive or rotate the rotor to pump fluid, liquids, materials and slurries from the inlet to the discharge. The motor can be any suitable motor know in the art that would be capable of driving the rotor at suitable rotational velocities.

As shown in FIGS. 1-5, the housing is curved and includes an inlet and a discharge or outlet. The inner surface of the housing is generally cylindrical and has a diameter that is larger than the diameter of the rotor. The inlet is disposed along a radial axis of the rotor on the bottom of the housing, which enables the fluid or materials to be sucked or drawn into the housing based on the rotation of the rotor. The discharge is disposed 90 degrees offset from the inlet (i.e., in a direction tangential to the rotor), which enables the fluid or materials to be pumped out of the housing.

As shown in FIGS. 6-11, the rotor includes a back plate, a conical center portion (hub) and a plurality of blades. The rotor can be cast, molded, forged, machined or formed in any suitable manner. Thus, the back plate, the conical center portion and the plurality of blades can be formed as a unitary one-piece member. The rotor can be an alloy, steel, stainless steel, aluminum, zinc, bronze, rubber, plastic or any other suitable material or combination of materials. Moreover, it is noted that the rotor can be any suitable mater or design. Thus, while the rotor is preferable a unitary one-piece member, the rotor can be formed from in multiple steps or by multiple pieces that are assembled in any suitable manner.

In one embodiment, the back plate is a generally circular plate having a first side (defining a first planar surface), a second side (defining a second planar surface) and an outer circumferential edge. The first or upper side faces the interior of the housing and has a protrusion or shaft extending therefrom. The protrusion is connected to or connectable to a drive shaft from the drive motor. The second side has the plurality of blades disposed thereon. As shown in FIG. 8, the back plate extends form the center of the rotor about the same length as the rotor, and thus covers the entire rotor blade length. In other words, the plurality of blades defines a radial diameter, and the back plate has a diameter that is the same as or about the same as the radial diameter of the back plate. However, it is noted that the radial diameter of the back plate can be between 0.3 and 1.0 the radial diameter defined by the plurality of blades, depending on the particle size, or any other parameter. This configuration (i.e., a “full size” back plate) prevents fluid from escaping the rotor and facilitates pushing the fluid circumferentially towards the outlet of the rotor and discharge. Moreover, the back plate helps reduce recirculation by maintaining fluid distribution inside the volume of the rotor, and prevents leakage and energy losses between the rotor and upper side of the housing. The back plate also helps reduce static pressure loss, which contributes to higher pressure differential and head developed by the rotor.

As shown in FIGS. 6-11, the conical center portion is a cone disposed in the center of the rotor and facilitates fixing the rotor to the motor shaft. The cone is disposed on the second side of the back plate and is opposite to the protrusion. The conical center portion has a vertex and a base. The base is adjacent the back plate and tapers toward the conical vertex. As shown in FIG. 8, the base has a radius of approximately 10.6 inches and is generally circular. Thus, the base radially extends about 50 percent of the base plate. As shown in FIG. 11, the conical vertex of the hub forms an angle α of about 40 degrees. However, the size of the base of the conical center portion and the angle α formed by the conical vertex can be any suitable or desired size or angle.

The conical center portion helps hydraulically by causing suction which enables the fluid to flow inside the housing smoothly from the inlet and facilitates laminar movement towards the outlet or end of the rotor and subsequently to the discharge. This induction of laminar flow aids in reduction of eddy currents and recirculation inside the housing, increasing pump efficiency. The size of the conical center portion (length, diameter and angle) can depend on the particle size, allowing better clearances of the particles, as long as laminar flow can be maintained towards the discharge. The conical center portion also helps create better eddy current from the suction to the inlet of the rotor while preventing turbulence at higher flow rates than the best efficiency point allowing the pump a flow rate 140% of the design best efficiency point. The size of the cone can be reduced or increased to control power consumption.

As shown in FIGS. 6-11, the plurality of blades extends from the conical center portion and is disposed on the first side of the back plate. In this embodiment, the plurality of blades includes five (5) blades, but the plurality of blades can be any suitable number of blades that form a suitable eddy current. Each of the blades includes a first side, a second side, an end and a bottom surface. Each of the blades extends radially outwardly from the conical center portion and along a longitudinal direction from the back plate. Moreover, since the conical center portion is a cone having a sloping surface, each of the blades follows the sloping contour of the conical center portion, see FIG. 9 for example.

The first longitudinal side and a second longitudinal side are opposite each other. The first and second longitudinal sides extend in the longitudinal direction, generally parallel to the longitudinal axis of the rotor and taper away from each other in the radial direction. That is, as shown in FIG. 8, the first and second longitudinal sides are disposed about 1.5 inches apart adjacent the conical center portion and 2 inches apart adjacent the circumferential edge of the back plate. Accordingly, as can be understood, the first and second longitudinal sides separate about 0.5 inches in the radial direction. It is noted that the first and second longitudinal sides can separate in any manner desired or can be parallel, if desired. Moreover, if the size of the rotor is changed, the change in separation of the first and second longitudinal sides can be changed accordingly. That is, in the embodiment, the change in the separation of the first and second longitudinal sides is 33 percent. In other words, the separation between the first and second longitudinal sides at the peripheral edge of the back plate if 33 percent larger than the separation of the first and second longitudinal sides adjacent the conical center portion.

As shown in FIGS. 6, 7, 9 and 11, each of the blades tapers upwardly from the peripheral edge of the back plate to the conical center portion. The bottom surface of each blade extends from a first end to a second end. The first end is adjacent the conical center portion and the second end is adjacent to outer surface. The second end preferably is higher than the first end when measured from the second side of the back plate. For example, in one embodiment, the first end is approximately 3.17 inches from the back plate and the second end is 5 inches from the back plate. However, it is noted that the first and second ends can be any suitable distance from the back plate. Moreover, if the size of the rotor is changed the change in heights of the first and second longitudinal ends can change accordingly. That is, in this embodiment the difference in the heights of the first and second ends is about 58 percent. In other words, the height of the second end is 58 percent higher than the height of the first end.

The outer surface of the blades can be seen in at least FIGS. 3, 4, 6, 7, 9 and 11. The outer surface is preferably a rectangular and is essentially parallel with a rotational axis of the rotor. As shown specifically in FIGS. 9 and 11, the outer surface forms a right angle (90 degrees) with the back plate. Moreover, as shown in FIG. 4, the outer surface extends generally parallel with the inner surface of the housing and is spaced a prescribed distance therefrom. Such a configuration enables particles to be disposed between the outer surface and the inner surface of the housing.

Additionally, as shown in FIG. 11, the bottom surface forms an angle α of 75 degrees with the outer surface and an angle β of about 15 degrees with a line parallel to the second side of the back plate. This tapering results in the conical center portion having a height from the second side of the back plate that is greater than the height of the first end and less than the height of the second end. Thus in one embodiment, the conical center portion has a height of 4.27 inches. Thus, as can be understood, the height of the conical center portion is about 83 percent of the height of the second end and about 38 percent greater than the height of the first end. However, the height of the conical center portion can be any suitable height.

Thus, as can be understood, the height of each of the blades increases from the center of the rotor towards the outside diameter or the peripheral edge of the back plate, on the suction side of the rotor. This structure enhances the eddy currents for improved suction of fluid and creates clearance for larger particle sizes. The rotor blade height at outside diameter is kept close to the height of the discharge or the diameter of the discharge so as to be capable of pushing fluids directly into the discharge. This configuration reduces leakage, recirculation and pressure losses. The tapering blade height also helps reduce the torque, and thus reduce the power consumed versus uniform blade height from center to outer diameter. The outer blade height can also be varied in proportion to the outlet diameter of the housing, keeping the dimensions similar if desired.

As shown in FIG. 4, each of the blades is spaced a predetermined distance from the housing. Generally, the clearance between the blades and the housing is kept at an additional 10-15% of the maximum particle size that is estimated to be in the material. This enables the rotor to pass particles of significant size while reducing the wear of the blades in the rotor.

A rotor having five blades is the preferable number of blades to reduce eddy current formation and recirculation between the rotor blades. It has been found that too few blades can cause turbulence and may not enable higher flow rates to create the required pressure differential. Too many blades may reduce clearances prohibiting larger size particles from passing through the pump and may reduce fluid volume allowable for ideal flow rate. However, the rotor can have any suitable number of blades that will enable some flow with a suitable amount and size of particles to pass through the housing.

Embodiments described herein reduce Net Positive Suction Head (NPSH) because the embodiments can handle lower suction pressures and subsequent cavitation significantly better due to smoother streamlines relative the conventional systems. This improves the suction performance of the pump and reduces the chances of cavitation and pump damage.

As can be understood, embodiments of the pumps described herein do not rely on the centrifugal principle of conventional pumps. Instead of a low tolerance impeller of a conventional pump, the pumps described herein use a specific geometric, recessed rotor to create a vortex of fluid or slurry like that of a tornado. That is, the Eddy Pump operates on the tornado principle. The tornado formed by the Eddy Pump and the rotor generates a very strong, synchronized central column of flow from the pump rotor to the pump inlet and creates a low-pressure reverse eddy flow from the pump inlet to the pump discharge. This action also results in an area of negative pressure near the pump seal. The negative pressure allows the pump to achieve zero leakage.

Further open rotor design described herein has high tolerances that enable any substance that enters the intake to be passed through the discharge without issues. This translates to a significant amount of solids and debris that passes through without clogging the pump. In one embodiment, the pump is capable of pumping up to 70% solids by weight and/or slurries with high viscosity and high specific gravity.

The configuration of the rotor so as to be recessed also creates eddy current that keeps abrasive material away from critical pump components. This structure improves pump life and reduces pump wear.

The tolerance between the rotor and the housing easily allows the passage of a large objects significantly greater than that of a centrifugal pump. For example, in a 2-inch to 10-inch Eddy Pump the tolerance ranges from 1-9 inches.

The embodiments described herein can have additional advantages, such as low maintenance, minimal downtime, low ownership costs and no need for steel high-pressure pipeline.

Since the Eddy Pump is based on the principle of Tornado Motion of liquid as a synchronized swirling column along the center of intake pipe that induces agitated mixing of solid particles with liquid, suction strong enough for solid particles to travel upwards into the housing or volute and generating pressure differential for desired discharge is created. This eddy current is formed by the pressure differential caused by the rotor and strengthened by turbulent flow patterns in the housing or volute and suction tube. Eddy currents are strengthened by the presence of solid particles which increase the inertial forces in the fluid. The formation of the eddy depends on the suspended solid particles that causes suction. Unlike conventional vortex pumps, the rotor directly drives the fluid through the pump with no slip. The Eddy Pump uses the movement of particles and the wake induced from these solid particles to generate Eddy Current and induce suction. Hence, efficiency is 7-10% better than conventional vortex pumps, with respect to horsepower. The eddy current generated by the Eddy Pump ensures steady movement of the mixture that leads to excellent non-clumping capabilities and the power to pump a very high concentration of solids, up to 70% by weight, and highly viscous fluids.

The drive motor is conventional component that are well known in the art. Since drive motor is well known in the art, this structure will not be discussed or illustrated in detail herein. Rather, it will be apparent to those skilled in the art from this disclosure that the components can be any type of structure and/or programming that can be used to carry out the present invention.

General Interpretation of Terms

In understanding the scope of the present invention, the term “comprising” and its derivatives, as used herein, are intended to be open ended terms that specify the presence of the stated features, elements, components, groups, integers, and/or steps, but do not exclude the presence of other unstated features, elements, components, groups, integers and/or steps. The foregoing also applies to words having similar meanings such as the terms, “including”, “having” and their derivatives. Also, the terms “part,” “portion,” or “element” when used in the singular can have the dual meaning of a single part or a plurality of parts. Also as used herein to describe the above embodiment(s), the following directional terms “rearward”, “top”, and “bottom”, as well as any other similar directional terms refer to those directions of the Eddy Pump. Accordingly, these terms, as utilized to describe the present invention should be interpreted relative to the Eddy Pump.

The term “configured” as used herein to describe a component, section or part of a device includes hardware and/or software that is constructed and/or programmed to carry out the desired function.

The terms of degree such as “substantially”, “about” and “approximately” as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed.

While only selected embodiments have been chosen to illustrate the present invention, it will be apparent to those skilled in the art from this disclosure that various changes and modifications can be made herein without departing from the scope of the invention as defined in the appended claims. For example, the size, shape, location or orientation of the various components can be changed as needed and/or desired. Components that are shown directly connected or contacting each other can have intermediate structures disposed between them. The functions of one element can be performed by two, and vice versa. The structures and functions of one embodiment can be adopted in another embodiment. It is not necessary for all advantages to be present in a particular embodiment at the same time. Every feature which is unique from the prior art, alone or in combination with other features, also should be considered a separate description of further inventions by the applicant, including the structural and/or functional concepts embodied by such features. Thus, the foregoing descriptions of the embodiments according to the present invention are provided for illustration only, and not for the purpose of limiting the invention as defined by the appended claims and their equivalents. 

What is claimed is:
 1. A pump rotor comprising: a hub having a rotational axis; a back plate having a planar surface; and a plurality of blades extending from the hub and disposed on the back plate, each of the plurality of blades having an outer surface essentially parallel to the rotational axis of the hub, and a first end adjacent the hub and a second end distal from the hub, the first end having a height from the planar surface that is less than a height from the planar surface of the second end, the plurality of blades configured to cause a synchronized central column of flow.
 2. The pump rotor of claim 1, wherein the back plate extends an entire length of each of the plurality of blades.
 3. The pump rotor of claim 1, wherein the plurality of blades defines a radial diameter, and the back plate has a diameter that is between 0.3 and 1.0 the radial diameter defined by the plurality of blades.
 4. The pump rotor of claim 1, wherein the hub is conical.
 5. The pump rotor of claim 4, wherein a conical vertex of the hub defines an angle of about 40 degrees.
 6. The pump rotor of claim 1, wherein a central portion of the hub has a height from the planar surface that is greater than the height of the first end and less than the height of the second end.
 7. The pump rotor of claim 1, wherein each of the plurality of blades includes a bottom surface between the first end and the second end, and the bottom surface and the outer surface form an angle of about 75 degrees.
 8. The pump rotor of claim 1, wherein the first end has a first width and the second end has a second width, the first width being less than the second width.
 9. The pump rotor of claim 1, wherein the outer surface is rectangular.
 10. The pump rotor of claim 1, wherein the pump rotor is configured to be disposed in a housing and the bottom surface is configured to spaced from an inner surface of the housing.
 11. A pump, comprising: a housing having an intake and a discharge; and a rotor including a hub, a back plate, and a plurality of blades extending from the hub and disposed on the back plate, each of the plurality of blades having an outer surface essentially parallel to a rotational axis of the hub, and a first end adjacent the hub and a second end distal from the hub, the first end having a height from a planar surface of the back plate that is less than a height from the planar surface of the second end, the plurality of blades configured to cause a synchronized central column of flow.
 12. The pump of claim 11, wherein the back plate is configured and arranged to prevent fluid leakage between the between the rotor and the housing.
 13. The pump of claim 11, wherein the hub is conical and configured to enable laminar flow movement towards the discharge.
 14. The pump of claim 13, wherein a conical vertex of the hub defines an angle of about 40 degrees.
 15. The pump of claim 11, wherein the height of the second end is substantially similar to a height of the discharge.
 16. The pump of claim 11, wherein the plurality of blades defines a radial diameter, and the back plate has a diameter that is between 0.3 and 1.0 the radial diameter defined by the plurality of blades.
 17. The pump of claim 11, wherein a central portion of the hub has a height from the planar surface that is greater than the height of the first end and less than the height of the second end.
 18. The pump of claim 11, wherein each of the plurality of blades includes a bottom surface between the first end and the second end, and the bottom surface and the outer surface form an angle of about 75 degrees.
 19. The pump of claim 11, wherein the first end has a first width and the second end has a second width, the first width being less than the second width.
 20. The pump of claim 11, wherein the outer surface is rectangular. 